Method and system of repairing a wall

ABSTRACT

A device and method of repairing a hole a wall or any other surface that includes an insert or patch that is passed through the hole and adhered to an inner surface of the wall. An adhesive may be disposed on the insert to adhere the insert to the inner surface of the wall. At least one opening may extend through the insert for permitting a user to press the insert against the inner surface of the wall. A plug, cover or backer may also be provided for blocking the opening extending through the insert prior to filing the hole with a filler. The insert may also include a plurality of spaced keyholes that extend therethrough for receiving and fixing a filler or joint compound in the hole. Since the hole in the wallboard is completely filled with filler it is restored to its original condition and fire rating.

PRIORITY

This non-provisional application claims the benefit of the provisional application having Ser. No. 60/634,751 filed on Dec. 9, 2005 and incorporated herein in its entirety by reference.

FIELD OF THE INVENTION

The invention relates generally to wall repair and more particularly to patches for patching a hole in a wall surface, wherein the wall surface is generally restored to its original condition.

BACKGROUND OF THE INVENTION

Every year thousands of homes are built or remodeled. The walls of these homes are typically covered by nailing or screwing gypsum wallboard, drywall or sheetrock to wood or steel wall studs. This technique results in a wall that is generally termed a hollow wall. Typically, gypsum wallboard is given a fire rating that is dependent upon the construction materials of the wallboard and its thickness.

If the gypsum wallboard is compromised, via a crack or hole, the fire rating of the wallboard is drastically reduced. When the wallboard is comprised do-it-yourselfers and professionals have to contend with repairing the damaged wallboard. Wall surface repairing systems or patches are known and typically consist of two basic types. The first type uses a plastic or metal mesh patch that is placed over the hole in the wallboard. Once the patch is positioned a filler compound, such as joint compound, is spread over the patch with a putty knife. There are two distinct disadvantages to this type of wall surface repair. First, only a thin layer of filler or joint compound covers the hole making that portion of the wallboard unusable to support picture frames and other structures. Second, since the filler is applied over the patch, which is above the surface of the wall, there is almost always a noticeable bulge extending away from the wall surface.

The second type of wall surface repairing system or patch includes cutting a new portion of the wall surface material slightly larger than the hole. Next, the insert is placed over the hole and a line is drawn around the new wallboard material. A saw is then used to cut along the new line around the hole, thereby forming a new larger hole. The insert or new wall material is then inserted and fastened, typically with screws or clips, into the newly formed hole. A flexible patch may then be placed over the wall surface and the new wall material to fill any gaps that may exist between the adjacent wall materials. Filler or joint compound is then spread over the new wall material and patch. The disadvantage to this type of wall surface repair is that it is time consuming and expensive. In most cases the insert materials are not readily available and must be purchased in larger amounts then will be used. If a patch is used there is generally a noticeable bulge in the wallboard over and around the repaired area.

A wall surface repair kit having a patch that may be adhered to an inner surface of a damaged wallboard is also known. Once the patch is adhered to the inner surface of the damaged wallboard a filler or joint compound is disposed in the hole and pressed against the patch. The filler is allowed to dry and sanded smoothed. Unfortunately, the patch has a pair of smooth opposed surfaces. As a result, the filler cannot attach to the patch and has a tendency to slump. The slumping creates a void in the newly filled hole that must be filled with fresh filler. This step has to be repeated until the hole is completely filled. Another problem with this system and method is that the patch is generally flexible and easily deformable by the filler. Yet another problem with these types of wall surface repair kits is that they do not return the wallboard to a pre-compromised fire rating.

What is needed is a device and method of repairing a hole in a wallboard that does not slump, thereby accelerating the speed of repairing a wall, is inexpensive and restores the wallboard its original fire rating without bulging away from the surface of the wall surface.

SUMMARY OF THE INVENTION

The device and method of repairing a hole in gypsum wallboard or any other surface includes an insert or patch having a pair of opposed surfaces. One of the opposed surfaces has an adhesive disposed thereon for adhering the insert to an inner surface of the wall. At least one opening extends through the insert for permitting a user to insert his or her finger through the insert in order to press the insert against the inner surface of the wallboard. The insert and the edges of the hole extending through the wallboard define a pocket for receiving a filler or joint compound. A plug, backer and/or cover may also be provided for blocking the opening extending through the insert prior to filing the pocket with filler. The insert may include a plurality of spaced keyholes that extend therethrough for receiving and fixing the filler or joint compound in the pocket and against the insert thereby, resisting sloughing of the filler and ensuring that the insert remains in place while the filler dries. The backer may also include at least one keyhole extending therethrough for receiving a portion of the filler. Once the insert, plug and filler are disposed on the wallboard, the filler is allowed to dry and sanded smooth and flush with an outer surface of the wallboard. Since the hole in the wallboard is completely filled with filler it is restored to its original condition and fire rating.

The above summary of the invention is not intended to describe each illustrated embodiment or every implementation of the invention. The figures in the detailed description that follows more particularly exemplify these various embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:

FIG. 1 is a perspective view of an embodiment of the invention which includes an insert, a stop, and a backer;

FIG. 2 is front plan view of the insert according to an example embodiment of the invention;

FIG. 3 is a rear plan view of the insert according to an example embodiment of the invention;

FIG. 4 is a front plan view of the stop according to an example embodiment of the invention;

FIG. 5 is a rear plan view of the stop according to an example embodiment of the invention;

FIG. 6 is a front perspective view of an example embodiment of the insert with keyholes, an opening and living hinge;

FIG. 7 is a perspective view of an example embodiment of the insert extending partially through an opening in a wall surface;

FIG. 8 is a perspective view of an example embodiment of the insert with a cover partially lifted from an adhesive surface of the insert;

FIG. 9 is a perspective view of an example embodiment of the insert with a cover partially lifted from an adhesive surface of the insert; and

FIG. 10 is a perspective view of an example embodiment of the insert disposed to an inner surface of the wall with the stop and backer hanging from a tether to prevent the insert from falling into an interior of the wall.

While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION

In an embodiment of the invention, the system and method of repairing a hole in a wall or any other surface, generally indicated by the numeral 10, includes passing an insert 20 through a hole in a wall and coupling or adhering the insert 20 to an inner surface of the wall. Filler or joint compound is then disposed in the hole and pressed against the insert 20. Filler is added and sanded or smoothed until it is flush with an outer surface of the wall. The final result is a wall that is repaired to a like new condition.

Referring to an example embodiment of the invention illustrated in FIGS. 1-3 and 6-10, the insert 20 has at least a first 21 and a second 22 generally planar and at least generally opposed surfaces. At least one of the opposed surfaces 21 or 22 may have an adhesive (not shown) disposed on at least a portion thereof for adhering the insert 20 to the inner surface of the wall. In another embodiment of the invention, fasteners may extending through a portion of the wall and into the insert 20, such that insert 20 is disposed generally adjacent to an inner surface of the wall. Other means of attaching, coupling and/or adhering the insert 20 to an inner surface of the wall is envisioned within the spirit and scope of this invention.

Referring to FIGS. 8 and 9, a cover 24 may be disposed on the insert 20 and over the adhesive until such time that the insert 20 is going to be used. The cover 24 may comprise a generally flexible material that is generally resistant to becoming permanently fixed or adhered to the adhesive on the insert 20.

Referring to FIGS. 6-7, the insert 20 may include at lease one living hinge 26 formed therein to permit it to be more easily passed through a hole in the wall. The living hinge 26 may extend along a length or width of the insert 20. In one embodiment of the invention, as particularly illustrated in FIG. 7, the living hinge 26 may be disposed generally equal distances from edges to permit the insert 20 to be bent in half for insertion through the hole. However, other embodiments may include having a pair of living hinges formed into the insert 20. In yet another embodiment of the invention, at least two or more living hinges 26 may intersect each other such that the insert 20 may be folded upon itself in various configurations for insertion through smaller or oddly shaped holes.

The insert 20 may also include at least one opening 30 extending therethrough for receiving a finger of a user during use. Once the insert 20 is disposed through the hole in the wall a user may extend their finger through the opening 30 and press the insert 20 against the inner surface of the wall. The opening 30 may be disposed in a generally central portion of the insert 20, such that a user's finger has access to and can generally reach every part of the insert 20. The opening 30 may have any shape or design that will facilitate a user to adhering the insert 20 to the inner surface of the wall.

The insert 20 may be manufactured from a foam, cardboard, mesh, or other like material. The insert 20 may have any size or shape to accommodate any size and/or shape hole in a wall.

In one embodiment, after the insert 20 is adhered to the inner surface of the wall a plug or backer 31 may be provided for blocking the opening 30. The backer 31 may comprise of the same material as the insert 20. The backer 31 may have an area slightly larger than an area of the opening 30 extending through the insert 20. In one embodiment, the backer 31 may be inserted into the opening 30 and held in place by friction or pressure. In another embodiment, an adhesive may be disposed on one of its surfaces such that it can be adhered to at least a portion of the insert 20 adjacent to the opening 30. In yet another embodiment, the backer 31 may be adhereable to the adhesive on the insert 20.

Once the insert 20 and backer 31 are disposed together to the inner surface of the wall they, together with the edge of the hole, define a pocket for receiving the filler or joint compound. In one embodiment of the invention, the insert 20 and/or the backer 31 may include at least one spaced keyhole 32 extending therethrough for receiving the filler or joint compound. As the filler is disposed in the pocket at least a portion of it passes through the at least one keyhole 32 and eventually dries securing the filler to the inert 20, which provides added strength to the filler.

Once the filler is dry it is smoothed or sanded flat with an outer surface of the wall, thereby leaving no noticeable bulge. The hole is completely filled with new filler restoring the wall surface to its original condition.

In one embodiment of the invention, a stop 40 may be coupled to the insert 20 and the backer 31 by a tether 42. The stop 40 may have a shape and configuration similar to the insert 20. The tethered stop 40 remains adjacent to the outer surface of the wall to prevent the insert 20 from falling into the interior of the wall. If the insert 20 happens to fall the stop 40 engages at least a portion of the edges of the hole, thereby stopping the insert 20 and enabling a user to retrieve it.

In one embodiment, the stop 40 may include first 44 and second 46 opposed generally planar surfaces. The stop 40 may also include an adhesive (not shown) disposed on at least a portion of at least one of its surfaces 44 or 46. The adhesive permits the stop 40 to be used in conjunction with the insert 20 to fill a hole generally larger than the insert 20. The stop 40 may include at least one living hinge extending along at least a portion thereof to permit it to be folded and inserted through the hole in the wall. The stop 40 may also include at least one keyhole 48 extending therethrough for receiving filler or joint compound disposed in a pocket formed by the insert 20 and the stop 40. The stop 40 may be manufacture from a material similar to the insert 20.

The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and it is therefore desired that the present embodiment be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than to the foregoing description to indicate the scope of the invention. 

1. A wall repair system for repairing a hole in a wall having an inner surface and an outer surface, said system comprising: an insert that is insertable through the hole in the wall, the insert having opposed surfaces with at least one of the opposed surfaces having an adhesive disposed thereon for adhering the insert to the inner surface of the wall, said insert having at least one keyhole extending therethrough; said insert having at least one opening extending therethrough for receiving a finger of a user, wherein once the insert is disposed through the hole in the wall a user extends their finger through the opening and presses the insert against the inner surface of the wall; a plug disposable over the opening, the plug having at least one keyhole extending therethrough; an adhesive disposed on one of an opposed surfaces of the plug such that it can be adhered to at least a portion of the insert, wherein once the insert and plug are disposed together they define a pocket in the wall; and a filler for filling the pocket in the wall and flowing through the at least one keyholes of the insert and plug, such that the filler dries thererin securing the filler to the inert and plug.
 2. The system of claim 1, further comprising at least one fastener extending through a portion of the wall and into the insert such that insert is disposed generally adjacent to an inner surface of the wall.
 3. The system of claim 1, further comprising a cover removably disposed on the insert and over the adhesive until such time that the insert is going to be used.
 4. The system of claim 1, further comprising at least one living hinge formed therein such that the insert has a plurality of portions, the living hinge permitting it to be passed through the hole in the wall.
 5. The system of claim 1, wherein opening is disposed in a generally central portion of the insert, such that a user's finger has access to and can generally reach every part of the insert.
 6. The system of claim 1, wherein the insert is manufactured from a foam, material.
 7. The system of claim 1, further comprising a sanding means for sanding the filler flat with an outer surface of the wall, thereby leaving no noticeable bulge.
 8. The system of claim 1, further comprising a stop coupled to the plug by a tether such that stop remains adjacent to the outer surface of the wall to prevent the insert from falling into an interior of the wall.
 9. The system of claim 8, further comprising an adhesive disposed on at least a portion of at least one of opposed surfaces of the stop to, in conjunction with the insert, fill a hole generally larger than the insert.
 10. The system of claim 8, wherein the stop includes at least one living hinge extending along at least a portion thereof to permit it to be folded and inserted through the hole in the wall.
 11. The system of claim 10, wherein the stop includes at least one keyhole extending therethrough for receiving the filler.
 12. A method of repairing a hole in a wall, said method comprising the steps of: folding an insert and positioning it through the hole in the wall; unfolding the insert and placing a finger through at least one hole extending therethrough; pressing on the insert to adhere it to an inner surface of the wall such that at least a portion of the hole is blocked; covering the at least one hole with a plug; filling a pocket formed by the insert, plug and the hole in the wall with filler, said filler extending through at least one keyhole extending through the insert and through at least one keyhole extending through the plug; smoothing the filler with a smoothing means such that the filler is flush with the wall leaving no noticeable elevation.
 13. A wall repair system for repairing a hole in a wall having an inner surface and an outer surface, said system comprising: an insert that is insertable through the hole in the wall, the insert having an adhesive disposed thereon for adhering the insert to the inner surface of the wall, said insert having at least one keyhole extending therethrough; and a filler for inserting into and filling the hole, said filler being capable of flowing through the at least one keyhole, such that the filler dries thererin securing the filler to the inert.
 14. The system of claim 13, wherein the insert includes an opening extending therethrough for receiving a finger of a user pressing the insert against the inner surface of the wall.
 15. The system of claim 14, further comprising a plug disposable over the opening to at least partially block the opening thus preventing the filler from flowing therethrough.
 16. The system of claim 15, wherein the plug has at least one keyhole extending therethrough for receiving the filler.
 17. The system of claim 15, further comprising an adhesive disposed on one of an opposed surfaces of the plug such that it can be adhered to at least a portion of the insert.
 18. The system of claim 13, further comprising at least one living hinge formed on the insert such that it has a plurality of portions, whereby the living hinge permits it to be passed through the hole in the wall.
 19. The system of claim 13, wherein the insert is manufactured from a foam, material.
 20. The system of claim 13, further comprising a sanding means for sanding the filler flat with an outer surface of the wall, thereby leaving no noticeable bulge. 